Torque limited decoupler

ABSTRACT

A decoupler assembly with a torsional damping system and a torque limiter. The torsional damping system has a torsion spring that facilitates transfer of rotary power into a hub. The torque limiter is wrapped about the torsion spring and radially expands with the torsion spring as a magnitude of the rotary power transmitted through the torsion spring increases. Contact between the torque limiter and another structure in the decoupler assembly halts radial expansion of the torsion spring.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. Ser. No.12/818,630 filed Jun. 18, 2010 now U.S. Pat. No. 7,975,821, which is acontinuation application of U.S. patent application Ser. No. 11/814,934,filed Jul. 27, 2007 now U.S. Pat. No. 7,766,774, which is a U.S.National Stage Entry of International Application No. PCT/CA2006/000129filed Feb. 3, 2006, which claims the benefits of U.S. ProvisionalApplication Ser. No. 60/649,520, filed Feb. 3, 2005. The entiredisclosure of each of the above applications are incorporated byreference as if fully set forth in detail herein.

FIELD

The present disclosure relates to a torque limited decoupler.

BACKGROUND

An automotive vehicle engine transfers a portion of the engine output toa plurality of belt driven accessories utilizing an endless serpentinebelt. Typically, each component includes an input drive shaft and apulley coupled to a distal end of the drive shaft for driving engagementwith the belt. An example of such a belt driven accessory is analternator.

A decoupler is operatively coupled between the pulley and the alternatorto allow the alternator drive shaft to “overrun” or rotate at a fasterspeed than the pulley and to allow the speed of the pulley to oscillatewith respect to the alternator drive shaft due to oscillations in theengine speed. Examples of decouplers are disclosed in U.S. Pat. No.6,083,130, issued to Mevissen et al. on Jul. 4, 2000, U.S. Pat. No.5,139,463, issued to Bytzek et al. on Aug. 18, 1992 and InternationalPatent Application No. WO 2004/011818.

In PCT application no. WO 2004/011818, the decoupler reduces torsionalfluctuations in the endless drive system. However, in certainapplications in which the engine has an aggressive start profile orduring conditions of rapid acceleration during a wide open throttleshift, the torques transmitted will over-stress the torsion springreducing long term durability of the decoupler.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

According to one aspect of the present disclosure, a decoupler assemblyis provided for transferring torque between a shaft and a drive belt.The decoupler assembly includes a hub configured to be fixedly securedto the shaft. A carrier is rotatably mounted on the hub. A torsionspring extends between the hub and the carrier for transferring torquetherebetween. A pulley is rotatably coupled to the hub. The pulley hasan inner surface formed therein. A clutch spring is secured to thecarrier and has a plurality of helical coils frictionally engaging withthe inner surface of the pulley to selectively couple the hub andpulley. The torsion spring and the clutch spring are mounted co-axiallyand wound in opposite senses enabling the clutch spring to expand intogripping engagement with the inner surface during acceleration of thepulley relative to the hub and to contract out of gripping engagementwith the inner surface during deceleration of the pulley relative to thehub, while enabling the torsion spring to absorb minor torsionalvibrations without decoupling the pulley from the hub. A torque limiter,in the form of a sleeve, is fitted about the torsion spring and is sizedto limit expansion of the torsion spring enabling the torsion spring tofully couple the hub with the pulley at or above a predetermined torque.

According to another aspect of the present disclosure, the torquelimiter is in the form of a wire coil, which is fitted about the torsionspring and is sized to limit expansion of the torsion spring enablingthe torsion spring to fully couple the hub with the pulley at or above apredetermined torque.

According to a further aspect of the present disclosure, a decouplerassembly is provided with a hub, a drive member, a torsional dampingsystem and a torque limiter. The hub that is configured to be coupled toa shaft for rotation therewith. The drive member is disposedconcentrically about the hub and is configured to drivingly engage anendless power transmitting member to permit rotary power to betransferred between the drive member and the endless power transmittingmember. The torsional damping system is disposed between the drivemember and the hub and has a torsion spring that facilitates transfer ofrotary power into the hub. The torque limiter is wrapped about thetorsion spring and radially expands with the torsion spring as amagnitude of the rotary power transmitted through the torsion springincreases. Contact between the torque limiter and another structure inthe decoupler assembly halts radial expansion of the torsion spring.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purpose only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a front view of an engine of an automotive vehicleincorporating a decoupler assembly according to one aspect of theinvention;

FIG. 2 is an enlarged fragmentary sectional view of the decouplerassembly;

FIG. 3 is an exploded perspective view of a clutch spring in thedecoupler assembly of FIG. 2;

FIG. 4 is an exploded perspective view of the clutch spring and carrierassembly in relation to the torque limiter and torsion spring of thedecoupler assembly of FIG. 2;

FIG. 5 a perspective view of the clutch spring of the decoupler assemblyof FIG. 2;

FIG. 6 is a perspective view of the carrier of the decoupler assembly ofFIG. 2;

FIG. 7 is a perspective view of the clutch spring and carrier assemblyof FIG. 2;

FIG. 8 is a perspective view of a second embodiment of the torquelimiter of the decoupler assembly of FIG. 2;

FIG. 9 a is a perspective view of a third embodiment of the torquelimiter of the decoupler assembly of FIG. 2;

FIG. 9 b is a perspective view of an alternate third embodiment of thetorque limiter of the decoupler assembly of FIG. 2;

FIG. 10 is an exploded perspective view of the decoupler assembly of afourth embodiment of the decoupler assembly of the present invention;

FIG. 11 is an exploded perspective view of the clutch spring and carrierassembly in relation to a torque limiter and torsion spring of thedecoupler assembly of FIG. 10;

FIG. 12 a perspective view of the clutch spring of the decouplerassembly of FIG. 10;

FIG. 13 is a perspective view of the carrier of the decoupler assemblyof FIG. 10; and

FIG. 14 is a perspective view of the clutch spring and carrier assemblyof FIG. 10.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

An engine for an automotive vehicle is generally indicated at 10 inFIG. 1. The engine 10 includes a crankshaft 12 driving an endlessserpentine belt 14, as commonly known by those having ordinary skill inthe art. The engine 10 also includes a belt driven accessory 16 drivenby the belt 14. Described in greater detail below, a decoupler assembly20 is operatively assembled between the belt 14 and the belt drivenaccessory 16 for automatically decoupling the belt driven accessory 16from the belt 14 when the belt 14 decelerates relative to the beltdriven accessory 16 and allowing the speed of the belt 14 to oscillaterelative to the belt driven accessory 16. Additionally, a detaileddescription of the structure and function of a decoupler assembly can befound in applicant's U.S. Pat. No. 6,083,130, which issued on Jul. 4,2000 and PCT Application No. WO 2004/011818, the contents of which areincorporated herein by reference.

Referring to FIGS. 2 and 3, the decoupler assembly 20 generally includesa hub 22, a pulley 50, a clutch assembly 70, a torsion spring 90 and atorque limiter 110. In the first embodiment, the torque limiter 110 ispreferably a sleeve.

Hub 22 has a generally cylindrical body 28 having an axially extendingbore 24 and a flange 26 at one end thereof. Flange 26 has a generallyhelical first slot 46 on an inner face thereof. Since the slot 46 ishelical, the slot 46 will have a step. The bore 24 is configured forfixedly securing the hub 22 to a drive shaft extending from the beltdriven accessory 16.

A pulley 50 is rotatably journaled to the hub 22. A ball bearingassembly 57 is coupled between the pulley 50 and the hub 22 at a distalend while a bushing journal 102 mounts the pulley 50 on thecircumferential face of flange 26. The bearing assembly 57 isconventional comprising an inner race, an outer race and a plurality ofball bearings rollingly engaged therebetween. The pulley 50 typicallyincludes a plurality of V-shaped grooves 66 formed on the outerperiphery for engaging and guiding the belt 14. Other belt or chainprofiles may be utilized to facilitate other drive configurations, wellknown in the art.

A one-way clutch assembly 70 is operatively coupled between the hub 22and the pulley 50. The clutch assembly 70 includes a clutch spring 71and a carrier 75. The clutch spring 71 includes a plurality of helicalcoils 72. Preferably, the clutch spring 71 is formed from an uncoated,spring steel material and has a non-circular cross-section to improvefrictional contact. Most preferably, the cross-section of clutch spring71 is rectangular or square. The clutch spring 71 is press fitted intofrictional engagement with the inner surface 56 of the pulley 50.Preferably, a lubricant similar or compatible with grease used in theball bearing assembly 57 is applied to minimize wear between the clutchspring 71 and the inner surface 56 of the pulley 50.

The carrier 75 is rotatably mounted on the hub 22. The carrier 75 isgenerally ring shaped and has an inner face 78, a bore 80 and an outercircumferential surface 82. A slot 84 is formed on the inner face 78 andis configured to retain an end of the clutch spring 71. A generallyhelical second slot 86 is also formed on the inner face 78 and inside ofslot 84, defining a second locating surface 88 and a step.

An annular thrust washer 39 is seated against the end of the carrier 75and abuts against the inner bearing race of bearing assembly 57. Theouter periphery of the thrust washer 39 is circular with a step 41 tocomplementarily fit with a tab. Thrust washer 39 has one or more radialor circumferential serrations 43 to engage hub 22 and mechanically lockthe thrust washer 39 to the hub 22 to prevent relative motiontherebetween.

A helical torsion spring 90 is axially compressed between the hub 22 andthe carrier 75. The torsion spring 90 and the clutch spring 71 areco-axial and typically coiled in opposite directions. In certainapplications, the torsion spring 90 and clutch spring 71 can be wound inthe same sense to produce a desired decoupling action. One end of thetorsion spring 90 is retained in the first slot 46 of the hub 22 and theother end is retained in the slot 86 of the carrier 75. Axial forces dueto the compression of the torsion spring 90 retain the carrier 75 inabutting engagement with the thrust washer 39.

Typically, the shaft of the hub 22 has an area of reduced diameter 23 toprovide clearance between the torsion spring 90 and the shaft 28 of hub22 to prevent uncontrolled contact and friction wear at the interfacebetween shaft 28 and torsion spring 90. Thus, the torsion spring 90allows relative movement between the carrier 75 and the hub 22 toaccommodate minor variations in the speed of the pulley 50 due tooscillations in the operating speed of the engine. The oscillations arenot sufficient to activate the clutch assembly 70.

A torque limiter 110 is wrapped about the torsion spring 90 in asurrounding relation. Preferably, torque limiter 110 has a split oropening 112 and a circumferentially extending shoulder step 114.Shoulder step 114 configures the torque limiter 110 to complementarilyfit with bushing 102 mounted on the flange 26 of hub 22. In a firstpreferred embodiment, torque limiter 110 is an organic resinousmaterial, preferably a Nylon™ material, with or without reinforcementmaterial such as glass fibres, etc. Torque limiter 110 has a thicknessselected to take up the play between the torsion spring 90, the clutchspring 71 and the inside diameter of the pulley 50. As torque increases,the torsional spring 90 expands outwardly until physically constrainedby the torque limiter 110 against the clutch spring 71 and the insidediameter of bore 56. When the radial clearance between the torsionspring 90, torque limiter 110, the clutch spring 71 and the inside bore56 of the pulley 50 is closed, the spring 90 is prevented from furtherexpanding, locking the decoupler 10, coupling the hub 22 with the pulley50. In other words, the torque limiter 110 limits the amount of outwardexpansion of the torsion spring 90, preventing overloading of thetorsion spring 90. The amount of radial expansion of the torsion spring90 can be calculated and the torque limiter 110 can be designed toensure that the torque transferred through the torsion spring 90 ismaintained below a predetermined torque value.

A second embodiment of the sleeve is illustrated in FIG. 8. Torquelimiter 110′ is a closed metal ring. The metal ring would only expand toa relatively small degree, directly limiting outward expansion of thetorsion spring 90.

A third embodiment of the sleeve is illustrated in FIG. 9 a. Torquelimiter 110″ has a plurality of axially elongate openings 116 spacedcircumferentially spaced about the torque limiter 110″. The openings 116enable the grease lubricant to travel outwardly to the clutch spring 71.

An alternative third embodiment of the sleeve is illustrated in FIG. 9b. The torque limiter 110* has a series of circumferentially spacedopenings 116* and 117. Preferably, openings 116* are elongate andopenings 117 are circular and spaced in a regular pattern, resemblingdimples on a golf ball. Additionally, torque limiter 110* has anintegrally extending radial flange 119 that acts a thrust bearing.

A cap 100 is attached to the end of pulley 50 for preventingcontaminants from entering the decoupler assembly 20 and for retainingthe lubricant within the decoupler assembly 20.

In operation, the engine 10 is started and the pulley 50 is acceleratedand rotated in a driven direction by the belt 14 driven by the engine10. Acceleration and rotation of the pulley 50 in the driven directionrelative to the hub 22 creates friction between the inner surface 56 ofthe pulley 50 and preferably all of the coils 72 of the clutch spring71. It should be appreciated that the clutch spring 71 will functioneven where at the onset at least one of the coils 72 of the clutchspring 71 is frictionally engaged with the inner surface 56 of thepulley 50. The clutch spring 71 is helically coiled such that thefriction between the inner surface 56 of the pulley 50 and at least oneof the coils 72 would cause the clutch spring 71 to expand radiallyoutwardly toward and grip the inner surface 56 of the pulley 50.Continued rotation of the pulley 50 in the driven direction relative tothe hub 22 would cause a generally exponential increase in the outwardlyradial force applied by the coils 72 against the inner surface 56 untilall of the coils 72 of the clutch spring 71 become fully brakinglyengaged with the pulley 50. When the clutch spring 71 is fully engagedwith the inner surface 56, the rotation of the pulley 50 is fullydirected toward rotation of the drive shaft 15 (FIG. 1) of the beltdriven accessory 16. Additionally, centrifugal forces help to retain theclutch spring 71 in braking engagement with the inner surface 56 of thepulley 50.

The rotational movement of the carrier 75 in the driven direction istransferred to the hub 22 by the torsional spring 90 such that thecarrier 75, thrust washer 39, hub 22, and the drive shaft 15 (FIG. 1)from the belt driven accessory 16 rotate together with the pulley 50.Additionally, the torsional spring 90 resiliently allows relativemovement between the carrier 75 and the hub 22 to accommodateoscillations in the speed of the pulley 50 due to correspondingoscillations in the operating speed of the engine 10.

When the pulley 50 decelerates, the hub 22 driven by the inertiaassociated with the rotating drive shaft 15 (FIG. 1) and the rotatingmass within the belt driven accessory 16 will initially “overrun” orcontinue to rotate in the driven direction at a higher speed than thepulley 50. More specifically, the higher rotational speed of the hub 22relative to the pulley 50 causes the clutch spring 71 to contractradially relative to the inner surface 56 of the pulley 50. The brakingengagement between the clutch spring 71 and the pulley 50 is relieved,thereby allowing overrunning of the hub 22 and drive shaft 15 (FIG. 1)from the belt driven accessory 16 relative to the pulley 50. The coils72 may remain frictionally engaged with the inner surface 56 while thepulley 50 decelerates relative to the clutch assembly 70 and the hub 22.The coils 72 of the clutch spring 71 begin to brakingly reengage theinner surface 56 as the pulley 50 accelerates beyond the speed of thehub 22.

In conditions of high loading, such as a fast engine start profileand/or rapid acceleration during a wide open throttle shift, the coilsof the torsion spring 90 will be urged to expand outwardly, due torelative rotation between the hub 22 and the pulley 50. The torsionspring 90 will expand, frictionally engaging the torque limiter 110which will then engage the clutch spring 71. Full frictionallyengagement is selected to occur at a predetermined torque value byselecting the thickness of the torque limiter 110. Once fully engaged,the hub 22 will be locked with the pulley 50 and torques above apredetermined torque value will be transmitted directly therebetween.Thus, the higher torques do not overstress the torsion spring 90 andultimately improving durability of the decoupler assembly 10.

Referring to FIGS. 10 to 14, a fourth embodiment of the torque limiter110 is illustrated. Elements common with the embodiment of FIGS. 2 and 3retain the same reference number.

In this embodiment, the torque limiter 110′″ is in the form of a wirecoil spring. Torque limiter 110′″ is positioned about the torsion spring90. Preferably, torque limiter 110″ is formed of a small gauge wire,compared to torque spring 90, with a square or rectangularcross-section. The gauge and dimensions of torque limiter 110′″ areselected such that any play which would otherwise be present betweentorsion spring 90, clutch spring 71 and the inside surface 56 of pulley50 is substantially removed, while still allowing relative motionbetween torsion spring 90 and clutch spring 71. Further, the coils oftorque limiter 110′″ allow grease, or any other lubricant, to traveloutwardly to the clutch spring 71.

It is presently preferred that the coils of torque limiter 110′″ bewound in the same sense of the coils of clutch spring 71, although thisis not essential to proper operation of decoupler 20.

As torque to pulley 50 increases, torsional spring 90 expands outwardlyuntil physically constrained by torque limiter 110′″. When the radialclearance between torsion spring 90, torque limiter 110′″, clutch spring71 and the inside surface 56 of pulley 50 is closed, spring 90 isprevented from further expanding, locking decoupler 20, coupling the hub22 with the pulley 50. In other words, torque limiter 110″ limits theamount of outward expansion of the torsion spring 90, preventingoverloading of torsion spring 90.

The amount of radial expansion of torsion spring 90 can bepre-determined and torque limiter 110′″ can be designed to ensure thatthe torque transferred through torsion spring 90 is maintained below apreselected torque value.

Referring to FIGS. 12 to 14, a second variant of the clutch assembly 70is illustrated. The clutch assembly 70 includes clutch spring 71′,comprising a helical coil, and a carrier 75′. Preferably, clutch spring71′ is formed from an uncoated, spring-steel material and the materialforming the helical windings 72 has a non-circular cross-section toimprove frictional contact. Most preferably, the cross-section of thehelical winding material is rectangular or square. Clutch spring 71′ ispress-fitted into frictional engagement with the inner surface 56 of thepulley 50. Preferably a lubricant, similar or compatible with the greaseused in the ball bearing assembly 57, is applied to minimize wearbetween the clutch spring 71′ and inner surface 56 of the pulley 50.

Carrier 75′ is rotatably mounted on the hub 22 and carrier 75′ isgenerally ring shaped, with an inner face 78, a bore 80 and an outercircumferential surface 82. A slot 84′ is formed on inner face 78 and isconfigured to retain an end of the clutch spring 71′. A generallyhelical second slot 86 is also formed on the inner face 78 and inside ofslot 84, defining a second locating surface 88 and a step.

In this variant, the end of clutch spring 71′ is bent at 73 and 77. Slot84′ is complementarily configured to receive the end of the clutchspring 71′ and frictionally engage with the bends 73 and 77.

The bore 80 of carrier 75′ has a keyway 81 and a series of axiallyextending dimples.

The decoupler illustrated in FIGS. 10 to 14 operates in the same fashionas described with respect to the decoupler illustrated in FIGS. 1 to 9.

In conditions of high loading, such as a fast engine start profileand/or rapid acceleration during a wide open throttle shift, the coilsof the torsion spring 90 will be urged to expand outwardly, due torelative rotation between hub 22 and pulley 50. The torsion spring 90will expand, expanding torque limiter 110′″ in turn, which will thenfrictionally engage the clutch spring 71. Full frictional engagement isselected to occur at a predetermined toque value by selecting thethickness of the windings of torque limiter 110.

Preferably, decoupler 20 further includes an adapter 104 which is pressfit into the inner race of bearing 57 and which allows decoupler 20 tobe fit to belt driven accessories with drive shafts of different sizesand/or to position decoupler 20 on the driven shaft to ensure correctalignment of grooves 66 with the serpentine belt. However, adapter 104is not necessary and decoupler 20 can be installed directly onto thedrive shaft of a belt driven accessory if the diameter of that driveshaft will properly engage the inner race surface of bearing 57 and/orif grooves 66 will be properly aligned with the serpentine belt.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology, which has been used, is intended tobe in the nature of words of description rather than of limitation. Manymodification and variations of the present invention are possible inlight of the above teachings. It is, therefore, to be understood thatwithin the scope of the appended claims, the invention may be practicedother than as specifically described.

What is claimed is:
 1. A decoupler assembly comprising: a hub; a drivemember disposed concentrically about the hub; a torsional damping systemdisposed between the drive member and the hub, the torsional dampingsystem comprising a one-way clutch and a torsion spring, the one-wayclutch comprising an input member, the torsion spring being formed ofwire and being configured to transmit rotary power between the inputmember of the one-way clutch and the hub; and means for limiting rotarypower transmitted axially through the wire of the torsion spring, themeans comprising a radially expandable torque limiter that is mounted tothe torsion spring.
 2. The decoupler assembly of claim 1, wherein theone-way clutch comprises a wrap spring.
 3. The decoupler assembly ofclaim 2, wherein the expandable torque limiter contacts an insidediametrical surface of the wrap spring when a predetermined maximumtorque is transmitted between the one-way clutch and the hub.
 4. Thedecoupler assembly of claim 1, wherein one or more openings are formedthrough the torque limiter.
 5. The decoupler assembly of claim 4,wherein the one or more openings comprises a helical slot that is formedbetween opposite axial ends of the torque limiter.
 6. The decouplerassembly of claim 1, wherein the torque limiter is formed of metal. 7.The decoupler assembly of claim 5, wherein the torque limiter comprisesa coil of wire.
 8. The decoupler assembly of claim 7, wherein the wireof the torque limiter has a generally square cross-section or agenerally rectangular cross-section.
 9. The decoupler of claim 5,wherein the wire of the torque limiter and the torsion spring are woundin the same sense.
 10. The decoupler of claim 1, wherein the drivemember comprises a pulley.
 11. A decoupler assembly comprising: a hub; adrive member disposed concentrically about the hub; a torsional dampingsystem disposed between the drive member and the hub, the torsionaldamping system comprising a one-way clutch and a torsion spring, theone-way clutch comprising an input member, the torsion spring beingconfigured to transmit rotary power between the input member of theone-way clutch and the hub; and a torque limiter wrapped about thetorsion spring and radially expanding with the torsion spring as amagnitude of the rotary power transmitted through the torsion springincreases, wherein contact between the torque limiter and the one-wayclutch halts radial expansion of the torsion spring at a predeterminedmaximum torque such that rotary power transmitted between the one-wayclutch and the hub in excess of the predetermined torque is at leastpartly transmitted frictionally between the torsion spring and theone-way clutch.
 12. The decoupler assembly of claim 11, wherein theone-way clutch comprises a wrap spring.
 13. The decoupler assembly ofclaim 12, wherein the torque limiter contacts an inside diametricalsurface of the wrap spring when the predetermined maximum torque istransmitted between the one-way clutch and the hub.
 14. The decouplerassembly of claim 11, wherein one or more openings are formed throughthe torque limiter.
 15. The decoupler assembly of claim 14, wherein theone or more openings comprises a helical slot that is formed betweenopposite axial ends of the torque limiter.
 16. The decoupler assembly ofclaim 11, wherein the torque limiter is formed of metal.
 17. Thedecoupler assembly of claim 16, wherein the torque limiter comprises acoil of wire.
 18. The decoupler assembly of claim 17, wherein the wireof the coil of wire has a generally square cross-section or a generallyrectangular cross-section.
 19. The decoupler of claim 18, wherein thewire of the coil of wire and the torsion spring are wound in the samesense.
 20. The decoupler of claim 11, wherein the drive member comprisesa pulley.